Unisex zippered packages with wide mouth and other features

ABSTRACT

The disclosure pertains to method for manufacturing reclosable packages, bags or pouches wherein, typically, a unisex zipper is looped so as to form a gap between the ends of the zipper and sealed inside of the package. The formation of the looped zipper segment causes the package to have a wide open mouth, and a natural tendency toward the open configuration.

This application is a continuation-in-part of application Ser. No. 13/193,030, filed Jul. 28, 2011, which claims priority under 35 U.S.C. §119(e) of U.S. provisional application Ser. No. 61/368,496 filed Jul. 28, 2010, the disclosures of which are hereby incorporated by reference in their entirety.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure pertains to unisex zippered reclosable packages with a wide mouth opening feature and/or easy open and/or easy close features. The present disclosure further pertains to wide mouth opening pre-made or horizontal form, fill and seal pouches. The present disclosure further pertains to pre-made or horizontal form, fill and seal pouches with pour spout reclosures.

2. Description of the Prior Art

Wide mouth gusseted packages are disclosed by U.S. Published Patent Application No. 2007/0258665 entitled “Wide Mouth Gusseted Packages”, published on Nov. 8, 2007 on behalf of Greco. While the Greco reference is well-adapted for its intended purposes, further improvements are sought with respect to simplifying the manufacturing process, particularly in transverse direction (TD) applications.

Additionally, while vertical form fill seal (VFFS) machines are well-adapted for their intended purposes, some VFFS applications which include transverse placement of the joined zipper can deal with issues such as a propensity for inner flange sealing exacerbated by poor heat transfer films; slide between the male and female zipper elements resulting in “inch worming” or open zippers jamming the equipment; lateral movement of elements resulting in offset elements that jam in the cassette or on the lip of the filling tube; poor stomping of joined zipper ends required to prevent slide of male and female elements or to promote ease of closure which then fail upon forcibly being opened to full mouth opening; premature knife wear as a result of cutting the two elements together; and zipper camber due to unbalanced flanges and the complexity of different sized flanges resulting in unreliable zipper transport or jumping off of or out of the guide, improper placement of the zipper, or unwanted zipper curvature.

Additionally, such applications may require jaw modifications in order to operate properly. The sealing of consumer side flanges to film may require more actions to take place under difficult operating conditions. The high heat conditions and the requirement to make these flange seals can also promote hot tack failure between the flanges and the film or flange-to-flange hot tacking.

Similarly, some current transverse direction zipper production applications may incur increased costs. These increased costs may occur due to joining equipment which increases scrap and reduces production speeds, increased sensitivity to winding conditions, the use of more expensive materials to prevent inner flange sealing, increased costs of sealant layers and the inherent complexity of working with male female profiles.

Moreover, the opening of sonic reclosable pouches may be restricted or smaller than the full mouth opening because of the zipper. In some transverse direction processes, it is necessary for the zipper to be shorter than the pouch in order to insert the zipper into the pouch. In addition, the zipper may be stomped which reduces the opening even further. Moreover, ease in opening is not always fully satisfactorily achieved by a pouch manufactured in a transverse direction application. Additionally, some single profiles do not close as well as some double zipper profiles.

In a pillow-type bag, the percentage mouth opening lost is relatively small compared to that of gusseted bags, yet the end stomps of the zipper still remove some the mouth opening in the pillow bag. Many current gusseted bags use a zipper that is short of the width of the bag's front panel, thereby restricting the opening size of the bag. In many applications, it is desirable that the opening of a pillow or gusseted bag be as large as possible to enable ease of scooping out or pouring out the product, or filling.

Other prior art includes U.S. Pat. No. 4,655,862 entitled “Method of and Means of Making Reclosable Bags and Method Therefor”, issued on Apr. 7, 1987 to Christoff et al.

OBJECTS AND SUMMARY OF THE DISCLOSURE

It is therefore an object of the present disclosure to provide improvements in wide mouth gusseted reclosable packages or bags.

It is therefore a further object of the present disclosure to provide improvements in gusseted bags with respect to increased width of mouth, increased ease of opening and/or increased ease of closing.

These and other objects are attained by a method which typically includes the steps of attaching a multi-track, self-mating reclosure across a web; providing a space or gap in the web between each end of the reclosure and each edge of the web, leaving enough room to form a fin or lap seal from the web material in the space or gap between the ends of the reclosure and the edges of the web; bringing the edges of the web together; so that the interlocking elements of the reclosure are in unmated opposing end-wise alignment with each other; and attaching the spaces or gaps together at each end of the web to form a fin seal or to form a lap seal.

These and other objects are further attained in the first and second embodiments of the disclosure by providing a package, pouch or bag, that includes a zipper reclosure which is typically a unisex style zipper, possibly including double profiles. The zipper or reclosure is attached to the pouch film by a transverse direction process. Because the zipper or reclosure is a unisex configuration, it can be fully attached to the film in a transverse direction application. The zipper or reclosure is attached to the width of the pouch film at the applicator position, but is configured so that there is a gap between the ends of the zipper or reclosure, whereby the ends of the zipper are spaced away from the fin seal or other seal. This gap makes it easier to form to fin or other seal, as compared to a similar embodiment without such a gap. The zipper or reclosure can have one or two flanges. The flanges are sealed to the pouch film in the transverse direction applicator.

These and other objects are attained in a third embodiment of the disclosure by applying a unisex zipper in the transverse direction to the width of the film web on a VFFS machine, whereby the zipper is configured so that there is a gap between the ends of zipper or reclosure, whereby the ends of the zipper are spaced away from the fin seal or other seal. The VFFS machine forms a package from the web. Often the machine will form a bag with side gussets.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the invention will become apparent from the following description and from the accompanying drawings, wherein:

FIG. 1 is a first perspective view of a first embodiment of the present disclosure, showing a reclosable package, using a unisex zipper or reclosure, in a closed configuration.

FIG. 2 is a second perspective view of a first embodiment of the present disclosure, showing a reclosable package in an open configuration.

FIG. 3 is a first perspective view of a second embodiment of the present disclosure, showing a reclosable package in a closed configuration.

FIG. 4 is a second perspective view of a second embodiment of the present disclosure, showing a reclosable package, using a double unisex zipper or reclosure, in an open configuration.

FIG. 5 is a cross-sectional view of a typical zipper (or reclosure) profile, a double unisex multiple alignment zipper.

FIG. 6 is a plan view of the reclosure in an open configuration across a width of the film or web.

FIG. 7 is a perspective view of the zipper or reclosure proximate to a lap seal.

FIG. 8 is a perspective view of the zipper or reclosure proximate to a fin seal.

FIG. 9 is a view of the reclosure of FIG. 6, further including a peel seal type zipper.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIGS. 1 and 2 disclose a first embodiment of the disclosure, including a package 10, formed from front wall 12 and rear wall 14 (including fin seal 60), and a double profile, unisex, multi-track, self-mating zipper or reclosure 20, illustrated as including two flanges 22, 24. FIGS. 3 and 4 disclose a similar second embodiment of the disclosure, including a package 10 and a unisex multiple alignment zipper or reclosure 20′, illustrated as including only one flange 22. As shown in FIG. 5, a unisex zipper or reclosure is one which can be folded and mated or interlocked with itself. It is envisioned that this reclosure is not limited to a zipper, and that various kinds of reclosures, such as those made by Aplix or hook-and-eye closures such as Velcro®, may be substituted for the zipper.

In both the first and second embodiments, the zipper 20 or 20′ is attached in a transverse direction to the film which is subsequently formed into a tubular shape thereby forming front and rear walls 12, 14 of package 10. This attachment is performed by a transverse direction applicator so that gap 23 is formed between the ends of the zipper 20 or 20′. FIG. 9 illustrates a variation of a zipper applied in a transverse direction across a web, further including a peel seal. All flanges are sealed to the pouch seal in the transverse direction.

As shown in FIG. 6, the zipper or reclosure 20 (or 20′) extends across the web 42. The zipper or reclosure 20 has first and second ends 20A, 20B which are separated from respective first and second edges 42A, 42B of the web 42. First space 61 (a portion of web 42 free of zipper 20) is formed between the first end 20A of zipper 20 and first edge 42A of web 42 and second space 62 (a portion of web 42 free of zipper 20) is formed between the second end 20B of zipper 20 and second edge 42B of web 42. As shown in FIG. 7, the edges 42A, 42B are brought together, thereby bringing spaces 61, 62 together, to form a lap seal 58, or, alternatively, as shown in FIG. 8, a fin seal 60, and additionally aligning the ends 20A, 20B of the zipper or reclosure 20 (or 20′) so that the interlocking elements proximate to the ends 20A, 20B of the zipper or reclosure 20 (or 20′) are placed into unmated opposing end-wise alignment, it is further envisioned within this disclosure that some embodiments may have only a single space 61, formed between first end 20A of zipper or reclosure 20 (or 20′) and first edge 42A of web 42, while the second end 20B of the reclosure 20 (or 20′) extends to second edge 42B of web 42, thereby eliminating space 62.

Both the first and second embodiments are produced by bringing the edges 42A, 42B of the web 42 together, thereby forming the pouch over a forming machine, such as, but not limited to, a vertical form fill seal (VFFS) fill tube, in pillow pouch fashion. The interlocking elements of the zipper (or reclosure) 20 or 20′ are placed into unmated opposing end-wise alignment with each other and first and second spaces 61, 62 are sealed to each other to form a fin seal 60 (or alternatively, a lap seal 58). The zipper 20 or 20′ is formed in a circular or tubular shape around the fill tube along with the film, with a gap 23 formed from spaces 61 and 62 between the ends 20A, 20B of the zipper 20 or 20′. This gap 23 makes it easier to form to the fin seal 60, the lap seal 58, or other seal, as compared to a similar embodiment without such a gap. As the pouch makes its way to the seal jaws of the VFFS apparatus (or similar apparatus), the package 10 is sealed above the zipper 20 or 20′ with the intention that the zipper 20 or 20′ is not hit by seal jaws forming the bottom of the subsequent package or pouch. The pouch can be cut to open or perforated to open, in the case of a consumer application, the top may frequently not be sealed, but merely cut off as the bottom of the next bag is sealed in the jaws. FIGS. 1 and 3 are illustrations of the package 10 with the zipper 20 or 20′ sealed and the package 10 closed above the zipper 20 or 20′. The package 10 may be left open and unfilled until a subsequent process. The formation of sequential bags or packages typically includes a cross-sealing step to form transverse direction seals at the top and bottom of the packages.

Because the pouch was preferably created without the zipper 20 or 20′ hitting the seal jaws of the VFFS equipment (or similar equipment), no permanent deformation of the zipper 20 or 20′ is expected. Therefore, the pouch created is essentially a sealed tube of film with a zipper 20 or 20′ attached in the transverse direction (not including the gap 23) along the entire circumference. Because the pouch was created with the film in tubular or circular form, the natural tendency of the film is typically to stay open in the tube shape, as shown in FIGS. 2 and 4. This is counteracted at the bottom of the package 10 by the bottom seal 30 created by the seal jaws to close the bottom of the bag. Prior art zippers with end stomps in the zipper, and wherein the zipper is attached to the pouch in the flat state, typically have a tendency to remain in a flat and interlocked state rather than a circular state.

The package 10 of first and second embodiments 10, 10′ is well-adapted as a consumer storage bag. The tendency of the package 10 to remain open when the zipper is not interlocked is desirable to many consumers who may hold the package or bag 10 with one hand, while the mouth of the bag remains wide open, which typically may make it much easier for the consumer, compared with a typical consumer bag.

This disclosure further includes improvements in form fill seal pouches in that the wide mouth feature of the pouch will allow the user to efficiently dispense the contents. In the first embodiment, reclosure of the pouch has been rendered easier through the double unisex profile zipper logic. The combination of double profile with a multi-alignment or unisex profile design creates the most forgiving package from a reclosure point of view. In either the first or second embodiment, the zipper could be designed to have a single flange or could have two flanges of equal or different lengths. The profile could be placed in the center of the two flanges to form a symmetric design but it could also be an asymmetric design.

In both the first and second embodiments, the use of a unisex zipper across a substantial portion of the web width (with the unisex zipper or reclosure being somewhat less long than the width of the web, thereby allowing a gap to be formed between the edges of the reclosure or zipper when the web is formed into a tubular shape with a fin seal) will produce a process that addresses many of the problems of current transverse directional processes, resulting in more process latitude and higher pouch making or process speeds and improved commercial prospects. In summary, the following concerns are expected to be addressed by the embodiments:

1. Sealing the zipper to the film from the zipper side in front of the tube eliminates or reduces propensity for inner flange sealing exacerbated by poor heat transfer films.

2. Sealing the zipper to the film from the zipper side eliminates or reduces the need for jaw modifications and tight registration requirements between zipper placement and the jaws.

3. Using one continuous unisex zipper element eliminates or reduces male/female slide between the elements and thus “inch worming”, open zipper or lateral movement causing jamming within the FFS equipment in the cassette or on the lip of the tube.

4. Elimination of end stomping is expected to achieve various advantages.

5. Knife life is increased because only a single element zipper is being used versus double the mass.

6. Using a continuous unisex zipper should reduce camber and promote straight zipper, good zipper transport and positioning of the zipper.

Moreover, production costs are typically reduced as less costly materials are used, no joining is required, less sensitive winding is required, and less complex profiles typically have reduced scrap.

The embodiments are typically expected to achieve many or all of the following advantages:

1. The resulting package will open up wide and stay open thereby allowing the user to use one hand to manipulate the bag, leaving one hand free for easier filling.

2. An improved form fill seal pouch allows for ease of product dispensing.

3. An improved and reliable transverse direction manufacturing process is achieved.

4. A fully open pouch may be achieved, without losses caused by gussets, stomping or a zipper shorter than full bag width.

5. Reduced cost zipper may be used in that the need for high density polyethylene is eliminated or reduced, the need for film may be eliminated or reduced, and linear low density polyethylene materials are expected to be able to be run at higher speeds.

6. The pouch may be easier to close in view of the unisex multiple alignment double zipper profile.

7. Zipper cutting and feeding may be simplified with reduced mass, no male/female slide, and reduced camber.

8. Zipper sealing is simplified due to the expected reduction or elimination of jaw modifications (particularly those which would otherwise be done in response to changes of film) and the expected reduction or elimination of hot tack problems.

9. As the zipper is not sealed in the jaw area, a more robust process is possible.

10. The need for ultrasonics may be reduced or eliminated.

The embodiment of the present disclosure illustrated in FIG. 9 adds hermeticity to the packages of the first and second embodiments by adding a peel seal coating to the flange above the profile. A unisex zipper segment 20 or 20′ (single or double flange zipper segments may be used) is applied in the transverse direction to the width of the film web 42 on a VFFS machine, but is configured so that spaces 61 and 62 form gap 23 when the zipper is in closed configuration, whereby the ends 40A, 40B of the zipper are spaced away from the fin seal 60 or other seal. The web 42 is formed by the VFFS machine. While not illustrated, the resulting package may include side gussets. As described with respect to the first and second embodiments, the use of a unisex zipper also allows for a full mouth opening for gusseted bags. However, the web 42 which forms the walls of the bag or package cannot be perforated if hermeticity is desired. Hermeticity can be achieved by the structure of FIG. 9 by the peel seal 50. The zipper or reclosure segment 20 includes first and second flanges 22, 24 as well as interlocking profile 48. Additionally, as indicated, a strip of peel seal material 50 is provided on first flange 24.

Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. 

What is claimed is:
 1. A method for manufacturing reclosable packages, including the steps of: providing a web moving in a machine direction; attaching a reclosure across the web in a transverse direction, wherein the reclosure includes an interlocking element and further includes first and second ends which are inwardly offset from respective first and second edges of the web, thereby providing respective first and second spaces of the web inwardly adjacent from respective first and second edges of the web, the first and second spaces of the web being outwardly adjacent from the respective first and second ends of the reclosure; and bringing the first and second spaces of the web together, thereby positioning portions of the interlocking element proximate to the first and second ends of the reclosure into unmated opposing end-wise alignment, the first and second ends of the reclosure being separated by a gap.
 2. The method of claim 1 further including a step of sealing the first and second spaces of the web to each other.
 3. The method of claim 2 wherein the step of sealing forms a fin seal.
 4. The method of claim 2 wherein the step of sealing forms a lap seal.
 5. The method of claim 1 wherein the reclosure is a unisex zipper.
 6. The method of claim 1 wherein the reclosure is a multiple alignment zipper.
 7. The method of claim 2 wherein the reclosure includes one flange.
 8. The method of claim 2 wherein the reclosure includes two flanges.
 9. The method of claim 1 wherein the step of bringing the first and second spaces of the web together further forms first and second walls of the package.
 10. A method of claim 1 wherein the reclosure includes a first flange and a peel seal on the flange.
 11. The method of claim 1 wherein the step of bringing the first and second spaces of the web together further includes forming the reclosure into loop which has a tendency to remain open.
 12. The method of claim 1 further including a step of cross-sealing between sequential packages.
 13. The method of claim 1 wherein the step of bringing the first and second spaces of the web together further includes the step of forming a tube. 